Image controller

ABSTRACT

An image controller structured for allowing inputs to be converted or translated into electrical outputs, one preferred controller structured with at least a sufficient number of sensors to aid in controlling three-dimensional objects and navigating a three-dimensional viewpoint shown by a display. An active tactile feedback vibrator is mounted as a component of the controller for providing vibration to be felt by a user. Inputs to the controller include a move forward command, a move back command, a move left command, a move right command, a move up command, and a move down command.

CROSS REFERENCE TO RELATED APPLICATIONS AND PATENTS

Priority Claim:

This Application is a Divisional Application of pending U.S. patentapplication Ser. No. 09/893,292 filed on Jun. 26, 2001.

U.S. application Ser. No. 09/893,292 is a Continuation of U.S.application Ser. No. 09/721,090 filed on Nov. 21, 2000 now U.S. Pat. No.6,310,606.

U.S. application Ser. No. 09/721,090 is a Continuation of U.S.application Ser. No. 08/677,378 filed on Jul. 5, 1996 now U.S. Pat. No.6,222,525.

U.S. application Ser. No. 08/677,378 is a Continuation-in-part of U.S.application Ser. No. 08/393,459 filed on Feb. 23, 1995 now U.S. Pat. No.5,565,891.

U.S. application Ser. No. 08/677,378 is a Continuation-in-part of U.S.application Ser. No. 07/847,619 filed on Mar. 5, 1992 now U.S. Pat. No.5,589,828.

This Application claims under 35 USC 120 the benefits to the aboveearlier Applications.

Herein Incorporated by Reference:

1) U.S. Pat. No. 6,222,525 of which the positive teachings anddisclosures are herein incorporated by reference.

2) U.S. Disclosure Document Number 381081 filed Nov. 22, 1995 which hasbeen placed in the file of U.S. Pat. No. 6,222,525 is hereinincorporated by reference for the positive teachings and disclosurestherein.

BACKGROUND OF THE INVENTION

1) Field of the Invention

This invention relates to structuring for sheet supported sensors andassociated circuitry in hand-operated graphic image controllers, andparticularly six degree of freedom computer image controllers whichserve as interface input devices between the human hand(s) and graphicimage displays such as a computer or television display, a head mountdisplay or any display capable of being viewed or perceived as beingviewed by a human.

2) Description of the Prior Art

Although there are many related physical-to-electrical hand-controlledinterfacing devices for use as image controllers taught in the priorart, none are structured similarly to the present invention, and noneoffer all of the advantages provided by the present invention.

In the highly competitive, cost-sensitive consumer electronicsmarketplace, the retail sales price of an item is normally closelycoupled to its manufacturing cost. It is generally agreed that theretail purchase price, or cost to the consumer, of any item influences aconsumer's purchasing decision. Thus, cost of manufacture ultimatelyinfluences the desirability and value of an item to the public at large.Generally, physical-to-electrical converters embodied in hand operatedelectronic image controllers such as trackballs, mouse type and joysticktype, increase in manufacturing cost as the number of degrees of freedomwhich can be interpreted between a hand operable input member and areference member increase.

Typically in the prior art, a three degree of freedom joystick typeinput device costs more to manufacture than a two degree of freedomjoystick, and a six degree of freedom (henceforth 6 DOF) joystick inputdevice costs significantly more to manufacture compared to a threedegree of freedom joystick. Likewise, a three or more degree of freedommouse-type controller costs more to manufacture than a standard twodegree of freedom mouse.

Manufacturing costs in such devices generally increase because, for atleast one reason, an increasing number of sensors is necessary for theadditional axes control, and the sensors in the prior art, particularlywith 6 DOF controllers having a single input member, typically have beenpositioned in widely-spread three dimensional constellations within thecontroller, thus requiring multiple sensor mounts and mount locationsand labor intensive, thus costly, hand wiring with individuallyinsulated wires from the sensors to a normally centralized circuitrylocation remote from the sensors.

In the prior art there exist 6 DOF controllers of a type having a handoperable, single input member moveable in six degrees of freedom foraxes control relative to a reference member of the controller. This typeof controller having the 6 DOF operable input member outputs a signal(s)for each degree of freedom input, and it is this type of 6 DOFcontroller which is believed to be by far the most easily used for 3-Dgraphics control, and it is with this type of 6 DOF controller that thepresent invention is primarily concerned.

In the prior art, 6 DOF controllers of the type having a hand operablesingle input member utilize individual sensors and sensor units(bi-directional sensors) mounted and positioned in a widely-spread threedimensional constellation, due to the failure to provide structuring forcooperative interaction with the sensors, so that some, most or all ofthe sensors may to be brought into or to exist in a generally singlearea and preferably in a generally single plane or planes. The prior artfails to provide structuring, such as a carriage member, for allowingcooperative interaction with sensors. The prior art fails to demonstratea carriage member which typically carries a sheet member connecting andsupporting sensors.

Another failure in prior art 6 DOF controllers of the type having a handoperable single input member is the failure to use or anticipate use ofinexpensive, flexible membrane sensor sheets, which are initially flatwhen manufactured, and which include sensors and conductive tracesapplied to the flat sheet structure. Such flat sheet membrane sensorscould be advantageously used as a generally flat sensor support panel,or alternatively in bent or three dimensionally formed shapes in 6 DOFcontroller structures which utilize three dimensional constellationsensor mounting and appropriate structures for cooperative interactionwith the sensors. The prior art in 6 DOF controllers of the type havinga hand operable single input member, has failed to use and anticipatethe use of, providing structures for cooperative interaction withsensors all in a single area which would allow use of a flat membranesensor sheet or a flat printed circuit board supporting the sensors andsensor conductors. The prior art in 6 DOF controllers of the type havinga hand operable single input member, has failed to use or anticipate useof flat sheet substratum as the foundation upon which to define or applysensors such as by printing with conductive ink, or to mount the sensorssuch as by plug-in or soldered connection of the sensors, and preferablyall of the required sensors for 6 DOF, and even further, the electricalconductors leading to and from the sensors in a printed or otherwiseapplied fixed position.

One prior art device which exemplifies many individual sensor unitsmounted in a widely-spread three dimensional constellation due to thesensor activators being located in many radically different elevationsand planes, is shown in U.S. Pat. No. 4,555,960 issued Dec. 3, 1985 toM. King.

The King device is a 6 DOF controller which has sensors, which are loadcells and rotary sensors such as potentiometers which are placed invarious locations scattered essentially all over the controller. Such“scattered”, individual sensor and sensor unit mounting locations arerequired in the King controller due to the failure to provide thestructures for cooperative interaction with the sensors to all belocated or brought into a single area of the controller, and thus thesensors in the King controller are not arranged in a manner allowingconventional automated installation such as on a generally flat circuitboard, or for printed circuit traces engaging or connecting the sensorsto be utilized, such as on a circuit board.

King also fails to anticipate the use of flexible membrane sensor sheetswhich include sensors and printed conductive traces which can bemanufactured inexpensively in a flat sheet form, and used in flat sheetform, or alternatively, bent into three dimensionally formed shapes toposition the sensors in three dimensional constellations. Thus thesensors and associated electrical conductors (wires) in the King deviceare believed to be required to be hand installed, and the wiresindividually applied to the sensors and then brought into a generallycentral area during the manufacturing of the King controller. Suchstructuring as in the King device is costly to manufacture, whichaccounts for, at least in part, why 6 DOF controllers are very costlywhen compared to two degree of freedom controllers.

Another problem in prior art controllers such as the King device isreliability. In the King device, reliability is less than optimum due tothe typical single input member 6 DOF prior art configuration ofcircuitry and sensors, because the hand wiring of sensors to remotecircuitry is subject to malfunctions such as wires breaking, cold solderjoints, and cross wiring due to error of the human assembler, etc.

Another problem in the circuitry and sensors as configured in typicalprior art controllers, particularly 6 DOF controllers such as that ofKing, is serviceability, testing, and quality control duringmanufacturing, such as at the manufacturing plant wherein testing isapplied before shipping, or after sales to the consumer such as withreturns of defective controllers. The typical widely-spread prior artsensor mounting and hand applied wiring associated with the sensorsrenders trouble shooting and repair more costly.

Another prior art disclosure believed somewhat relevant is taught inU.S. Pat. No. 5,298,919 issued Mar. 29, 1994 to M. Chang. The Changdevice is basically a six degree of freedom computer controller forcomputer graphics, and includes a generally flat plane printed circuitboard on which all of the sensors are mounted. However, as will becomeappreciated, in Chang's controller, the lack of a hand operable singleinput member operable in six degrees of freedom has many significantdisadvantages. Further, the Chang controller does not have a any inputmember capable of being manipulated in 6 DOF relative to any referencemember of the controller, which yields additional significantdisadvantages.

The Chang controller is structured as a mouse type input device having aroller ball on the underside requiring travel of the input device andhousing thereof along a surface for rolling the underside ball for inputof information pertaining to two axes of linear movement, which istypical of “mouse” type controllers. The Chang device includes a rotarythumb wheel mounted on the side of the housing to mimic linear movementof the housing along a third axis. The Chang device also includes asecond roller ball (trackball) exposed for manual rotation on the uppersurface of the housing, and upper trackball is provided to allow theuser to input information pertaining to rotation about the threemutually perpendicular or orthogonal axes conventionally referred to asyaw, pitch and roll.

Major disadvantages which I believe exist in the Chang device, which donot exist in the present invention, include the requirement that thetrackball housing be moved along a surface in order to input linearmoment information. This requirement of surface contacting travelprohibits the use of the Chang device as a completely hand heldcontroller, and prohibits the Chang controller from being incorporatedinto a multiple-purpose controller such as a hand held television remotecontroller or a conventional computer keyboard. Additionally,substantial physical space is required on a desk or table on which topropel a mouse type controller.

Another disadvantage of the Chang controller is that it is believed tobe difficult to use, or in other words, the mouse roller ball on theunderside of the housing which inputs linear moment information in somedirections, is not capable of inputs in all linear directions, and thusthe Chang device includes the thumb wheel off to the housing side whichis utilized to emulate, approximate or represent linear movement alongthe third axis. The hand movements required to move linearly utilizingpushing of the mouse housing for some directions, and the actuation ofthe thumb wheel for other directions is not intuitive and is thusconfusing and difficult for the user.

Further, a mouse type controller such as Chang's cannot provide thedesirable aspect of automatic return-to-center along the linear axes, orin other words, with a mouse, the user must actively move the mouse backto center (and center is often not easily determined by the user) sincethere are no feasible arrangements for the use of return-to-centersprings or resilient structuring.

Additionally, the Chang device appears relatively expensive tomanufacture, for at least one reason due to the use of six rotaryencoders, three of which are utilized for linear inputs. Rotary encodersare relatively expensive compared to many other sensor types. Encoderscan provide advantages in some instances for rotary inputs. Compared tosome other types of sensors, rotary encoders are not only moreexpensive, but have significant disadvantages as linear input sensors.

The Chang controller does not have a single input member such as oneball or one handle which can be operated (causing representativeelectrical output) in six degrees of freedom. Nor can any one Changinput member be manipulated (moved) relative to a reference member onthe controller in six degrees of freedom. Thus, the Chang device isfunctionally and structurally deficient.

Therefore, there exists a need for further improvements in the field ofsix degree of freedom controllers for graphics control such as on orthrough a computer and monitor or television screen or any display.

SUMMARY OF THE INVENTION

The following summary and detailed description is of best modes andpreferred structures for carrying out the invention, and although thereare clearly changes which could be made to that which is specificallyherein described and shown in the included drawings, for the sake ofbrevity of this disclosure, all of these changes which fall within thetrue scope of the present invention have not herein been detailed.

In order that 6 DOF controllers be more affordable, and for a user to beeasily able to control objects and/or navigate a viewpoint within athree-dimensional graphics display, I have developed improved, low-costhand operated 6 DOF controllers for use with a computer or computerizedtelevision or the like host device. The controllers provide structuringfor converting full six degrees of freedom physical input provided by ahuman hand on a hand operable single input member into representativeoutputs or signals useful either directly or indirectly for controllingor assisting in controlling graphic image displays. The presentcontrollers sense hand inputs on the input member via movement or forceinfluenced sensors, and send information describing rotation orrotational force of the hand operable input member in either directionabout three mutually perpendicular bi-directional axes herein referredto as yaw, pitch and roll, (or first, second and third); and informationdescribing linear moment of the hand operable input member along theaxes to a host computer or like graphics generation device for controlof graphics of a display, thus six degrees of freedom of movement orforce against the input member are converted to input-representativesignals for control of graphics images.

The present controllers include the hand operable input member definedin relationship to a reference member of the controller. The inputmember can be a trackball operable relative to a housing (referencemember) as described in my above mentioned co-pending application, oralternatively, the input member can be any handle fit to be manipulatedby a human hand, such as a joystick type handle, but in either case, theinput member accepts 6 DOF of hand input relative to the referencemember, and the converter acts or operates from the hand inputs to causeinfluencing of the sensors which inform or shape electricity to be usedas, or to produce such as by way of processing, an output signalsuitable for a host device to at least in part control the image on thedisplay of the host device.

The present 6 DOF controller provides structuring for sensors to belocated, in some embodiments, in a generally single plane, such as on asubstantially flat flexible membrane sensor sheet, or a circuit boardsheet. The use of flat sheet mounted or positioned sensors preferablyelectrically connected with fixed-place trace circuitry provides theadvantages of very low cost sensor and associated sensor circuitmanufacturing; ease in replacing a malfunctioning sensor or conductor byentire sheet replacement, and increased reliability due to theelimination of individually insulated wires to the sensors.

The use of sheet supported sensors and associated circuits enable theuse of highly automated circuit and sensor defining and locating,resulting in lower manufacturing costs and higher product reliability.The utilization of flat sheet substratum supporting the sensors, andpreferably sensor circuitry in conductive fixed-place trace form,provides many advantages, with one being the allowance of a short or lowprofile 6 DOF controller, and another, as previously mentioned, lowercost in manufacturing. In at least one preferred embodiment, all sensorsfor 6 DOF are positioned on one substantially flat sheet member, such asa circuit board sheet or membrane sensor sheet, and electricallyconductive traces are applied to the sheet members and engaging thesensors. The conductive traces can be used to bring electricity to thesensors, depending on the sensor type selected to be utilized, and toconduct electricity controlled, shaped or informed by the sensor to anelectronic processor or cable-out lead or the like.

As will be detailed in reference to a present embodiment of 6 DOFcontroller, the sensors and conductive traces can be manufactured on agenerally flat flexible membrane sensor sheet material such as anon-conductive plastic sheet, which then may or may not be bent into athree dimensional configuration, even a widely-spread 3-D sensorconstellation, thus sheet supported sensor structuring provides theadvantages of very low cost sensor and associated sensor circuitmanufacturing; ease in replacing a malfunctioning sensor or conductor byentire sheet replacement, and increased reliability due to theelimination of individually insulated wires to the sensors.

The present invention solves the aforementioned prior art problemsassociated with 6 DOF controllers having one 6 DOF input member, withmultiple, individually hand mounted and positioned sensors or sensorunits in widely-spread three dimensional constellations, and theproblems of hand applied wiring of individually insulated wire to theindividual sensors or sensor units. The present 6 DOF controller solvesthese problems primarily with sheet supported sensor structuring andmost associated circuitry on the sheet which is at least initially flatwhen the sensors and conductive circuit traces are applied; the sheetcircuitry and sensors being an arrangement particularly well suited forautomated manufacturing, and well suited for fast and simple test-pointtrouble shooting and single board or “sheet” unit replacement ifmalfunction occurs. Hand applying of the sensors and associatedelectrical conductors onto the flat sheet is not outside the scope ofthe invention, but is not as great of an advancement, for reasons ofcost and reliability, compared to utilizing automated manufacturingprocesses that are currently in wide use.

Automated manufacturing of circuit boards with fixed-place traceconductors, sensors, discrete electronic components and integrated chipsis in wide use today for television, computer, video and stereomanufacturing for example, and can employ the plugging-in of sensor andelectrical components with computer controlled machinery, and theapplication of conductive trace conductors onto the otherwisenon-conductive circuit board sheets is usually performed using automaticmachinery, wherein the solder or conductive material adheres to printedfluxed or non-etched areas where electrical connections and conductivetraces are desired, although other processes are used. Automatedmanufacturing of flat, flexible membrane sensor sheets is in wide usetoday for computer keyboards, programmable computer keypads, andconsumer electronics control pads, to name just a few for example.Flexible membrane sensor sheets are currently being manufactured by wayof utilizing non-conductive flexible plastics sheets, and printingthereon with electrically conductive ink when the sheets are layingflat, to define circuit conductors and contact switches (sensors).Usually, and this is believed well known, printed contact switches onflexible membranes utilizes three layers of plastic sheets for normalcontact pair separation, with a first contact on one outer sheet, and asecond contact of the pair on the opposite outer sheet, and a thirdinner sheet separating the aligned contact pair, but with a small holein the inner sheet allowing one contact to be pressed inward through thehole to contact the other aligned contact of the pair, thus closing thecircuit. A conductor trace of printed conductive ink is printed on eachof the outer sheets and connects to the contact of that sheet. Thecontacts are also normally defined with conductive ink. Although thisflexible membrane sensor structure in formed of multiple sheets stackedupon one another, it will herein generally be referred to as a membranesensor sheet since it functions as a single unit. The printed conductiveinks remain, or can be formulated to remain flexible after curing, andthis allows the flexible membrane sensor sheet to be bent without theprinted circuits breaking. Flexible membrane sensor sheets can be cutinto many shapes before or after the application of the sensors andassociated circuits.

For the purposes of this teaching, specification and claims, the term“sensor” or “sensors” is considered to include not only simple on/off,off/on contact switches, but also proportional sensors such as,proximity sensors, variable resistive and/or capacitive sensors, piezosensors, variable voltage/amperage limiting or amplifying sensors,potentiometers, resistive and optical sensors or encoders and the like,and also other electricity-controlling, shaping or informing devicesinfluenced by movement or force. Pressure sensitive variable resistancematerials incorporated into sensors applied directly on flexiblemembranes, circuit boards and sensor packages mounted on sheetstructures are anticipated as being highly useful as proportionalsensors and desirable in 6 DOF controllers of the types hereindisclosed.

For the purposes of this teaching, specification and claims, it isimportant to define the terms: “manipulate, operate and converter”.

The term “manipulate”, and all derivatives (manipulated, manipulating,manipulatable, manipulation, etc.), is used in the context of the inputmember being manipulatable in 6 DOF relative to the reference member.This means that the input member or handle can be linearly moved alongand/or rotated about the three mutually perpendicular axes in 6 DOF butit does not necessarily mean that sensors are being stimulated or thatthe device is outputting a representative signal. It only means that itcan be moved and/or rotated in such a manner. It may or may not bestimulating sensors or outputting information representative of thehandle manipulation. A handle capable of being “manipulated” in 6 DOFmeans only that it can be linearly moved and/or rotated relative to thereference member.

The term “operate”, and all derivatives (operated, operating, operable,operation, etc.) is used in the context of the input member beingoperable in 6 DOF relative to the reference member. This means that thehandle can be linearly moved along and/or rotated about the threemutually perpendicular axes in 6 DOF and it does necessarily mean thatsensors are being stimulated and that the device is outputting a signalrepresentative of the input operation.

The term “converter”, and all affiliated words and derivatives (convert,converts, converted, conversion, etc.) is used in the context of aphysical to electrical converter. Meaning this is a device that changes(converts) real world physical or mechanical movements and/or rotationsof the input member (input) into electrical signals (output) carryinginformation describing, at least in part, the nature of the input membermovement and/or rotation.

Also, for the purposes of this teaching, specification and claims, it isimportant to define the terms: “joystick-type” controller and“trackball-type” controller. The term “joystick-type” controller and theterm “trackball-type” controller represent two different kinds of handoperated input controllers which both have a hand operable input member(handle or trackball) which is operated relative to a reference member(base, shaft or housing). The difference in these two types ofcontrollers is: The input member of the joystick-type controller may bemanipulatable or operable in up to 6 DOF but the freedom of the inputmember is only to move or rotate within a limited range of travelrelative to the reference member; On the other hand, the input member ofa trackball type device, typically being spherical in shape, has anunlimited amount of travel about the rotational axes. A 6 DOFtrackball-type embodiment is illustrated in FIGS. 1-10, and 6 DOFjoystick type embodiments are illustrated in FIGS. 13-36.

A primary object of the invention is to provide a 6 DOF image controller(physical-to-electrical converter), which includes a single input memberbeing hand operable relative to a reference member of the controller,and the controller providing structure with the advantage of mountingthe sensors in a generally single area or on at least one planar area,such as on a generally flat flexible membrane sensor sheet or circuitboard sheet, so that the controller can be highly reliable andrelatively inexpensive to manufacture.

Another object of the invention is to provide an easy to use 6 DOFcontroller physical-to-electrical converter) which includes a singleinput member being hand operable relative to a reference member of thecontroller, and which provides the advantage of structure forcooperative interaction with the sensors positioned in a threedimensional constellation, with the sensors and associated circuitconductors initially applied to flexible substantially flat sheetmaterial, which is then bent or otherwise formed into a suitable threedimensional constellation appropriate for circuit trace routing andsensor location mounting.

Another object of the invention is to provide an easy to use 6 DOFcontroller, which includes a single input member hand operable relativeto a reference member of the controller, and which has the advantagethat it can be manufactured relatively inexpensively using sensors andassociated circuits of types and positional layout capable of beingassembled and/or defined with automated manufacturing processes on flatsheet material.

Another object of the invention is to provide an easy to use 6 DOFcontroller, which includes a single input member hand operable relativeto a reference member of the controller, and which has the advantagethat it can be manufactured using highly reliable automatedmanufacturing processes on flat sheet material, thus essentiallyeliminating errors of assembly such as erroneously routed wiringconnections, cold or poor solder connections, etc.

Another object of the invention is to provide an easy to use 6 DOFcontroller, which includes a single input member hand operable relativeto a reference member of the controller, and which has the advantagethat it can be manufactured using sensors and associated circuits onflat sheet material so that serviceability and repair are easily andinexpensively achieved by a simple sheet replacement.

Another object of the invention is to provide a 6 DOF controller whichis structured in such a manner as to allow the controller to be madewith a relatively low profile input member, which offers many advantagesin packaging for sale, operation in various embodiments and environments(such as a low profile 6 DOF handle integrated into a keyboard so thatother surrounding keys can still be easily accessed) and function of thedevice (such as still allowing room for active tactile feedback meanswithin a still small low handle shape). An example of an active tactilefeedback means is an electric motor with shaft and offset weight withina handle for providing active tactile feedback, as shown in drawing FIG.21.

Another object of the invention is to provide and meet theaforementioned objects in a 6 DOF controller which allows for theapplication and advantage of sensor choice. The invention can beconstructed with sensors as simple as electrical contacts or moresophisticated proportional and pressure-sensitive variable outputsensors, or the like. The printed circuit board provides great ease inusing a wide variety of sensor types which can be plugged into or formedonto the board with automated component installing machinery, and theflexible membrane sensor sheet can also utilize a variety of sensorssuch as contact pairs and pressure-sensitive variable output sensors(pressure-sensitive variable resistors) printed or otherwise placed ontoflexible membrane sensor sheets.

Another object of the invention is to provide and meet theaforementioned objects in a six degree of freedom controller providingthe advantage of versatility of complex movements wherein all threeperpendicular Cartesian coordinates (three mutually perpendicular axesherein referred to as yaw, pitch and roll) are interpretedbi-directionally, both in a linear fashion as in movement along or forcedown any axis, and a rotational fashion as in rotation or force aboutany axis. These linear and rotational interpretations can be combined inevery possible way to describe every possible interpretation of threedimensions.

These, as well as further objects and advantages of the presentinvention will become better understood upon consideration of theremaining specification and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a trackball type embodiment of the inventionwithin a housing specific for a carriage and the trackball.

FIG. 2 is a cross-sectional side view of the FIG. 1 embodiment taken atline 2.

FIG. 3 is a cross-sectional end view taken at line 3 of FIG. 1.

FIG. 4 is a partial illustration of the carriage, the trackball and atrack frame between two walls.

FIG. 5 is an illustration showing a portion of a slightly variedcarriage, the trackball, and a collet which is rotatable about thetrackball which can be used within the scope of the present invention. Arotary encoder is shown as an example of a sensor in contact with thebottom of the collet.

FIG. 6 is an illustration basically showing another form of therotatable collet.

FIG. 7 shows three mutually perpendicular axes herein referred to asfirst, second and third, or respectively roll, pitch and yaw axes, whichare shown having a mutual point of intersection at the center of theinput member which is shown as a trackball but may be any handmanipulated input member.

FIG. 8 is an illustration of a housing structured specific for thecarriage and trackball, and one which is generally flat-bottomed andthus structured suitably to rest upon a support surface such as a tableor desk when utilized. A broken outline indicates the possibility of anadditional extension which is ergonomically designed as a wrist andforearm rest.

FIG. 9 is the carriage and trackball in a band held housing sized andshaped to be grasped in a hand of a user while the user controls graphicimages with the controller.

FIG. 10 is the carriage and trackball housed in an otherwise relativelyconventional computer keyboard having well over 40 keys for thealphabet, numbers 1-9, a spacebar and other function keys.

FIG. 11 represents a display such as a computer or television withdisplay showing a cube displayed three dimensionally.

FIG. 12 is a partial cross-sectional end view of a joystick typeembodiment of the invention. This embodiment is or can be structuredidentically to the FIG. 1 trackball embodiment, with the exception of anelongated graspable handle engaged on an exposed portion of the ball.

FIG. 13 shows an exploded view of another joystick embodiment of thecurrent invention exhibiting structuring enabling use of a membranesensor sheet.

FIG. 14 shows a membrane sensor sheet in flat form.

FIG. 15 shows a membrane sensor sheet in the folded 3-D configuration.

FIG. 16 shows all sensors in mechanical flat mount and right angle mountpackages as they may be positioned on a rigid flat sheet, such as acircuit board sheet.

FIG. 17 shows a membrane sensor sheet in a variation where all 6 DOFsensors are positioned on a flat plane.

FIG. 18 shows structuring of the membrane sensor sheet as described inFIG. 17 as a novel appendage on an otherwise conventional membranesensor sheet such as is found in a typical modern computer keyboard.

FIG. 19 shows an external view of a 6 DOF controller in accordance withthe present invention positioned where the arrow key pad would be on anotherwise common computer keyboard housing.

FIG. 20 shows an exploded view of a two-planar embodiment havingrocker-arm actuators.

FIG. 21 shows a side view of the embodiment of FIG. 20.

FIG. 22 shows a perspective view of the rocker-arm actuators of theembodiment of FIGS. 20-21.

FIG. 23-25 show various side views of two-armed rocker arm actuators inoperation.

FIG. 26 shows a top view of a rocker arm layout and its reduced area byusing two one-armed actuators.

FIG. 27 shows a side view of a one-armed rocker actuator.

FIG. 28 shows an exploded view of the handle of the embodiment of FIGS.20 and 21.

FIG. 29 shows an otherwise typical computer keyboard membrane withcustom appendages to fit into and be actuated by the structures of theembodiment shown in FIGS. 20-28 located in the arrow pad region of anotherwise typical computer keyboard.

FIG. 30 shows a perspective view of a 6 DOF handle integrated into anotherwise typical remote control device such as are used to control TVs,VCRs, Cable Boxes, and some computers, etc.

FIG. 31 shows a perspective view of the device of FIG. 30 in dashedlines and an internal view of a membrane shaped to fit the embodimentshown in FIGS. 20-29.

FIG. 32 shows a side view of a 6 DOF two planar device using one circuitboard per plane for support of sensors and electronics with eightsensors located on a plane in the base and four sensors located on aplane in the handle.

FIG. 33 shows a perspective view of a third axis translation componentfor the embodiment shown in FIG. 32.

FIG. 34 shows a side view of the component of FIG. 34 in a carriage.

FIG. 35 shows a perspective view of the components shown in FIGS. 32-34.

FIG. 36 shows a side view of a two planar embodiment using circuitboards but having substantially different sensor placements andstructuring, with eight sensors located on a plane in the handle andfour sensors on a plane in the base.

FIG. 37 shows a side cross-section view of a typical right angle soldermount sensor package for a momentary-On switch sensor.

FIG. 38 shows a side cross-section view of a horizontal or flat soldermount sensor package containing a proportional pressure sensitiveelement internally.

FIG. 39 shows a side cross-section view of a proportional membranesensor having a metallic dome cap actuator in the non-activatedposition.

FIG. 40 shows a side cross-section view of a proportional membranesensor having a metallic dome cap actuator in the activated position.

FIG. 41 shows a side cross-section view of a compound membrane sensorhaving multiple simple On/Off switched elements piggy backed one on topof another.

FIG. 42 shows a side cross-section view of a compound membrane sensorhaving both a simple On/Off switched element and a proportional elementwhich are simultaneously activated.

FIG. 43 shows a side cross-section view of two compound sensors of thetype shown in FIG. 42 arranged to create a single bidirectionalproportional sensor.

FIG. 44 shows a side cross-section view of two unidirectionalproportional sensors electrically connected to form a singlebidirectional sensor with a central null area.

FIG. 45 shows a perspective view of a generic rocker arm actuatoroperating a bidirectional rotary sensor.

FIG. 46 shows a perspective view of a generic rocker arm actuatoroperating a bidirectional optical sensor.

FIG. 47 shows a perspective view of the sensors of FIGS. 45 and 46 asthey can be embodied within a handle.

FIG. 48 shows a side cross-section view of a novel structure foranchoring a membrane sensor in position and also for holding sensoractuating structures in position.

FIG. 49 shows an exploded view of the embodiment of FIG. 41.

FIG. 50 shows a median cross-section view of the embodiment of FIGS. 48and 49 but in a right angle variation.

BEST MODES FOR CARRYING OUT THE INVENTION

Referring now to the drawings in general, and particularly to drawingFIGS. 1 through 11 for a description a trackball-type embodiment 9exemplifying principles of the invention. Joystick-type embodimentsfurther exemplifying the principles of the invention are then describedas additional preferred embodiments of the invention.

With reference to FIGS. 1-4 in particular wherein trackball-typeembodiment 9, being a hand operable 6 DOF controller for outputtingcontrol information is illustrated showing a rectangular housing 10which is considered a reference member relative to which is operatedtrackball 12 which in this example is the hand operable single inputmember operable in full six degrees of freedom. FIGS. 2-3 beingcross-sectional views of the FIG. 1 embodiment showing housing 10 whichcan at least in part support, retain and protect moveable carriage 14.

As may be appreciated already from the above writing and drawings,carriage 14 is supported at least in part within housing 10 and withstructuring for allowing carriage 14 to be moveable or moved in alllinear directions relative to housing 10, for example, left, right,forward, rearward, up and down, and in the possible combinationsthereof. Furthermore, housing 10 may be specific for the present sixdegree of freedom controller as exemplified in FIGS. 1-3 and 8, or thehousing 10 of another functional device such as an otherwise typicalhand held remote control housing or computer keyboard housing as shownin FIGS. 9 and 10 respectively, and offering or including functions suchas keyboarding, cursor control, on/off, volume control, channel controland the like in addition to that offered by the present six degree offreedom controller. Housing 10 may be in effect the panel or panels of acontrol console of a vehicle or machine. Housing 10 may be any sizewithin reason, although trackball 12, any exposed part of carriage 14 orhousing 10 intended to be manually controlled or hand held should ofcourse be correctly sized to interface with the human hand or hands.When housing 10 is too large to allow easy use of the housing walls uponwhich to place carriage movement stops (stationary walls or posts tolimit movement of the carriage) or sensor actuators or sensor supportssuch as would be likely with the keyboard housing of FIG. 10 wherein thehousing side walls are a substantial distance apart, then walls,partitions or posts specific for these purposes may be placed in anydesired and advantageous location within housing 10 as shown for examplein FIG. 2 wherein actuators 100 and 104 are shown extending verticallyupward from the interior bottom of housing 10, inward of the interiorside walls of the housing, and supporting or serving as a switch/sensoractuator, or a second component of the sensor, such as a secondcomponent of a two piece proximity sensor for example. Actuator 100functions in conjunction with forward sensor 102, and actuator 104functions in conjunction with rearward sensor 106 in this example. FIG.3 illustrates for example the use of side walls 18 of housing 10 as thesensor actuators 116 and 120 or press plates for right sensor 118 andleft sensor 122. Housing 10 in most all applications will be made ofrigid or semi-rigid plastics for cost, weight and strengthconsiderations, although other materials might be functionally suitable.

Although it must be noted that within the scope of the inventioncarriage 14 functions may conceivably be provided with numerousstructures, carriage 14 is shown in the drawings as including a lowermember 20 and an upper member 22 positioned above lower member 20. Inthis example, lower member 20 is shown as a rigid sheet member such as acircuit board, but could be structured as a rigid sheet supporting aflexible membrane sensor sheet having at least circuitry in the form ofelectrically conductive circuit traces which are stationary on the sheetmember. Lower and upper members 20, 22 in this example are eachplate-like and rectangular, are in spaced parallel relationship to oneanother, are horizontally disposed, and are rigidly connected to oneanother via vertically oriented rigid connecting posts 24. Upper member22 and lower member 20 are preferably of rigid materials such as rigidplastics, as are connecting posts 24 which may be integrally molded asone part with upper member 22 and connected to lower member 20 utilizinga mushroom-head shaped snap connector end on each posts 24 snappedthrough holes in member 20, or with screws passed upward through holesin member 20 and threadably engaged in holes in the bottom terminal endsof posts 24. Glue or adhesives could be used to connect posts 24 tolower member 20. Typically four connecting posts 24 would be used asindicated in dofted outline in FIG. 1 although the posts could easily besubstituted with equivalent structures such as two walls, etc. Theseparate lower member 20 which is then attached to upper member 22,allows member 20 to be flat on each side and more suitably shaped andstructured to allow circuit traces and sensors to be applied utilizingautomated machinery, without upper member 22 being in the way. Uppermember 22 includes an opening 26 in which trackball 12 resides andextends partly therethrough, and opening 26 may include an annularraised lip or ring such as a threaded ring 28 or the like for engaging acooperatively structured collet 16 such as one having threading at thebottom edge thereof, or it may be an opening absent any raised lip orextending collet as illustrated in FIG. 8 wherein trackball 12 is shownextending upward through opening 26 in upper member 22. Trackball 12also might be exposed in great part (more than 50 percent) without usingcollet 16 by utilizing an arm extending upward from carriage 14 andpartially over trackball 12 is such a manner as to retain trackball 12in unison with carriage 14 for all linear movements. Collet 16, ifutilized, serves as an easily gripped member allowing the human hand tomove carriage 14 and thus trackball 12 in any linear direction desired,although when collet 16 is not utilized, trackball 12 can be grasped bythe fingers of the hand to also move carriage 14 in any lineardirection. If a graspable collet is not used, then the exposed portionof trackball 12 is available for grasping with the fingers to applyforce in any linear direction, much like a basketball player grasps abasketball in one hand or in the fingers.

Lower member 20 of carriage 14 preferably physically supports wheels,rollers, bearing or slide members or smooth surfaces which otherwise aidin supporting trackball 12 in a freely spherically rotatable manner, andin the example illustrated, three mutually perpendicular encoders(sensors) 124, 126, 128 mounted on the upper surface of lower member 20for sensing rotation, direction and amount of rotation of trackball 12about the yaw, pitch and roll axes include rotatable wheels upon andagainst which trackball 12 rests, and is thereby rotatably supported. Inmost applications, the weight of trackball 12 and its most commonpositioning within the supporting rotatable wheels of the encoderscauses sufficient frictional engagement between the encoder wheels andtrackball 12 so that rotation of the trackball causes rotation of one ormore of the encoders, depending upon the axis about which trackball 12is rotated. The structure of carriage 14 and collet 16 if the extendingcollet is used, is sufficiently close in fit to trackball 12 to render asubstantial link in linear movement between carriage 14, collet 16 andtrackball 12. In other words, linear movements in trackball 12 aresubstantially equal to linear movement of carriage 14 and collet 16. Itshould be noted that I consider collet 16 as shown in FIG. 2 and someother drawings, whether it is a fixed or rotatable collet (to bedetailed) to be part of carriage 14 since it is supported or fastened tocarriage 14 and moves therewith. As previously stated, carriage 14 issupported with structuring for allowing movement in all lineardirections relative to housing 10, for example, left and right which islinear movement along the pitch axis in this example; forward andrearward which is linear movement along the roll axis in this example;up and down which is linear movement along the yaw axis in this example;and in the possible combinations thereof, and sensors are positioned todetect and provide (output) information related to such linear movementsof carriage 14 relative to housing 10. Clearly since trackball 12 andcollet 16 are linked to move linearly with carriage 14, trackball 12 canbe moved linearly in all directions relative to housing 10, whereinhousing 10 is considered the reference member. I prefer carriage 14 tobe not rotatable relative to housing 10 since rotation interpretationsabout the three mutually perpendicular axes (see FIG. 7) are providedvia trackball 12 and encoders 124, 126, 128 for sensing sphericalrotation of trackball 12 about yaw, pitch and roll. Therefore, I prefercarriage 14 to be supported or retained in such a manner and byappropriate structure to allow carriage 14 to be moved linearly in allpossible directions, but prevented from being axially rotated relativeto housing 10 so that trackball 12 can be rotated when desired withoutcarriage 14 unintentionally being rotated, and this so the encoders (orwhatever rotational sensors which may be utilized) will be rotated. Iwould consider it to be within the scope of the invention if carriage 14was to be supported in a manner which would allow limited axial rotationthereof, although I believe this to be an undesirable aspect.

Although the structuring to physically support carriage 14 so it can bemoved in any linear direction can conceivably be accomplished throughnumerous structural arrangements, two are illustrated for example, witha first shown in FIGS. 1-4, and a second shown in FIG. 6. I prefer therebe a return-to-center aspect regarding carriage 14, and preferably acenter null associated with this return-to-center wherein no significantlinear sensor activation occurs. This carriage return-to-center and tocenter null can conceivably be accomplished with numerous structures,but one structure which should be readily understandable and thereforemakes a good example is to simply utilize on/off switches as thecarriage position linear sensors for moment related information output,with the switches including activation buttons which are outwardlyspring biased, wherein carriage 14 can be pushed against one of theswitches to the point of activating the switch (closing or opening a setof electrical contacts), which of course sends or outputs informationrelating to this event via allowing or interrupting current flow, andthe button spring being depressed by carriage 14 would then pushcarriage 14 back toward the center and the null position upon the userreleasing pressure toward that particular switch. Furthermore, asmentioned above, if such an on/off switch using spring biasing were tobe of a type which made a detectable click or snap upon being activatedby pressure from carriage 14, and this is a commonly available snapswitch, then this click or snap could be felt or heard by the user, andthus the user would be provided information alerting him of theactivation or possibly deactivation of the switch. Snapping or clickingmechanisms which are not sensors can of course be installed when sensorsof a type which are silent are used, and tactile or audible signalsindicating sensor activation or deactivation is desired.

With reference to FIGS. 2-3, expanded foam rubber 30 is shown placedagainst the bottom interior of housing 10 and underneath lower member 20of carriage 14. Snap or spring biased switches as described above may beused in conjunction with foam rubber 30. Foam rubber 30 is a resilientlycompressible and thus spring material. Foam rubber 30, and other springmaterials such as coiled compression springs, leaf springs and the likecould conceivably be used instead of foam rubber, however foam rubberfunctions well, is inexpensive, readily available and easily shaped orcut. I have even considered suspending carriage 14 on tension springshung from the underside interior of housing 10, but this seems to be anexcessively complicated structure compared to using foam rubber as shownand described. Foam rubber 30 in the example of FIGS. 2-3 is arectangular piece having a center cut-out or opening at 32 to allow forthe interaction of down sensor 110 shown mounted on the underside oflower member 20 with actuator 108 specific for interaction with downsensor 110 located beneath the sensor 110. The actuator 108 for downsensor 110 is sized to allow the abutment or actuation of the downsensor 110 no matter where carriage 14 has been moved laterally when theuser wishes to push down on carriage 14 to activate the sensor 110. Foamrubber 30 being compressible will allow the user to push down ontrackball 12 or collet 16, or possibly the exposed top of carriage 14(upper member 22) to push carriage 14 downward to activate the downsensor 110. This pushing downward compresses the foam rubber 30, andwhen the user releases the downward pressure, the foam rubber 30 beingresilient pushes carriage 14 upward again to deactivate the down sensor110 and to move carriage 14 into the center null position. Foam rubber30 in the example shown in FIGS. 2-3 is rectangular and slightly largerin all dimensions than the size of lower member 20, and the foam rubber30 is affixed to the underside of lower member 20 such as by glue ormechanical fasteners so that the foam is securely affixed to the lowermember (carriage). Since the foam rubber 30 is slightly larger than thelower member 20, the foam rubber 30 extends outward laterally beyond allperipheral sides of the lower member 20. This extending portion of thefoam rubber 30 serves as a spring bumper which as shown in FIG. 2 iscompressed against actuators 100, 104 (or housing side walls 18 undersome circumstances) prior to the sensors 102, 106 shown on the left andright being activated, and in the case of the FIG. 3 drawing iscompressed against the side walls 18 of housing 10 prior to the sensors118, 122 shown on the left and right being activated. When the userreleases the pushing pressure, the compressed foam rubber 30 will pushcarriage 14 back toward the center null position, as the foam rubber 30is normally in a partially extended state, being able to be compressedand to then spring back. The up sensor 114 shown in FIG. 2 is shownmounted on the top of the lower member 20, and the weight of carriage 14is normally sufficient to pull carriage 14 and sensor 114 downward awayfrom its actuator 112 upon release of upward pulling pressure by theuser, although a spring such as a foam rubber pad or the like couldconceivably be placed between the underside of the housing top panel andthe upper member 22 to push carriage 14 downward to deactivate the upsensor 114 if weight and gravity were insufficient or unavailable suchas in outer space. The actuator 112 for the up sensor 114 is shownsuspended from the interior underside of the housing top portion, and isa member which may be formed as an integral component of housing 10 ifdesired. The actuator 112 for the up sensor 114 may be simply a plate orpanel against which a snap switch mounted on carriage 14 strikes or ispressed against, or it may be a second component of the sensor, or maybe supporting a second component of the sensor such as the secondcomponent of a two piece proximity sensor, and this is generally true ofall of the actuators shown and described. Also generally true of all ofthe actuators shown and described is that they must be sufficientlylarge and or properly positioned be useful even when carriage 14 ismoved to any allowed extreme position.

In FIGS. 2-4 is track frame 34 located under the top of housing 10.Track frame 34 is free to be moved vertically within housing 10, whichwill allow carriage 14 to be moved vertically to activate the up or downsensors 114, 110. Additionally from FIGS. 2-3 it can be seen thatcarriage 14 is sized and shaped relative to housing 10 and componentswithin housing 10 such as the actuators to allow carriage 14 to be movedin all linear directions, although only in small amounts in the exampleshown. I prefer the linear movement requirements from the center null toactivating a sensor or sensors to be small, although the distances couldbe made substantial if desired. The track frame 34 is a structure whichcan be utilized to positively prevent axial rotation of carriage 14. Thefoam rubber 30 of FIGS. 2-3 being positioned tightly between eitherwalls or actuators or both on the four peripheral sides of the foamnormally serves to a satisfactory degree as an anti-axial rotationstructure for carriage 14, however, for more positive prevention ofaxial rotation of carriage 14, track frame 34 or like structure may beapplied. As shown in FIG. 4, track frame 34 is a rectangular frameopened centrally in which upper member 22 is slidably retained. Twooppositely disposed sides of frame 34 are abutted, but slidably so,against and between two stationary parallel walls which may be sidewalls 18 of housing 10 or partitions installed specific for thispurpose. The lower member 20 in this arrangement would be supported byresting on foam rubber 30, and if upper member 22 were pushed forward orrearward for example, frame 34 would slide between the walls 18. Frame34 can also move up and down sliding between the walls 18, but due tothe close fit, the frame 34 will not axially rotate between the walls18. The upper member 22 fits lengthwise snugly yet slidably between twooppositely disposed U-shaped track sides of frame 34 as can be seen inFIGS. 2 and 4, but is narrower than the width of the frame 34 as can beseen in FIGS. 3-4, and thus when upper member 22 is pushed forward andrearward (for example) it pushes frame 34 with it due to the close fitin this direction between the frame 34 and upper member 22, and whenupper member 22 is pushed left and right (for example) it slides in theU-shaped track portion of frame 34, as the frame 34 cannot move in thesedirections due to its close abutment against the parallel walls 18. Whenupper member 22 is moved up and down, track frame 34 moves up and downalso, as does the balance of carriage 14 and trackball 12. It should beremembered that in this example, upper member 22 and lower member 20 arerigidly tied together with connecting posts 24, and that the members 20and 22 constitute components of carriage 14, and that the carriage is tobe manually controlled linearly via a hand applying force to collet 16or the trackball or both, or possibly an exposed portion of the uppermember 22 as mentioned previously. It should be noted that a space 36 orclearance is provided between the upper portion of the housingsurrounding trackball 12, carriage 14 or collet 16 to allow movement ofcarriage 14 laterally, since carriage 14 and trackball 12 moveindependent of housing 10. The space 36 or crack may be covered withflexible or rubbery sheet material or any suitable boot or sealarrangement to exclude debris, or the space 36 (crack) may be kept(manufactured) narrow or small to be less likely to collect debris.

Another example of using foam rubber 30 is shown in FIG. 6 wherein thefoam 30 is located atop a stationary shelf 38 within housing 10, anddirectly under upper member 22 which rests atop of the foam rubber 30.Foam rubber 30 extends beyond shelf 38 inward as may be seen in thedrawing. The inward most edges of the foam rubber 30 are abutted againstthe vertical connecting posts 24 of carriage 14. Carriage 14 beingsupported by foam rubber 30 being between the underside of upper member22 and the top of the shelf 38 is allowed to be moved in all lineardirections, and the foam rubber 30 abutting connecting posts 24 andabutting the interior of the housing walls as shown functions as areturn-to-center and return to null arrangement much like that describedfor the FIGS. 2-3 structural arrangement. The shelf 38 in this exampleshould be on all interior sidewalls of housing 10, or at least undersome resilient foam placed about the periphery of carriage 14. It shouldbe noted clearance above upper member 22 and the top interior surface ofhousing 10 must be provided to allow upward movement of carriage 14 withpulling action to activate the up sensor 114, and the support forcarriage 14 such as the foam rubber must allow carriage 14 to move awayand to clear the activation of the up sensor 114 upon the termination ofthe upward pulling pressure on carriage 14, and this principle appliesin most if not all embodiments of the invention.

With reference to FIGS. 5-6 for a brief description of an optionalarrangement wherein collet 16 can be rotatably attached to upper member22 allowing collet 16 to be manually rotated about trackball 12, asopposed to being non-rotatably affixed to upper member 22 as in theFIGS. 1-3 embodiment. The rotatable collet of FIGS. 5-6 may at least forsome users be an easier process to achieve rotation about the yaw axisas compared to rotating trackball 12 at least in terms of rotation aboutyaw. The rotating collet may be able to rotate 360 degrees as in FIG. 5,or only in part rotatable as in FIG. 6 wherein collet 16 can only movethrough a short arc back and forth, being limited such as by amultiple-position rocker style sensor 158. Both of the collets 16 shownin FIGS. 5-6 are connected to the upper member 22 via a loose fit tongueand groove connection shown for example at 170, the tongue being anupward extension of upper member 22 and the groove being a component ofcollet 16 and engaged over the tongue. In FIG. 5 an optical encoder 168is shown as an example of a sensor in contact with the bottom of collet16 so that rotation of collet 16 in either direction rotates the opticalwheel of the encoder 168, this could be achieved by gear teeth aroundthe outer periphery of a drive wheel of encoder 168 mated to gear teetharound the bottom of collet 16, and the encoder outputs informationindicative of the direction and amount of rotation of collet 16 aboutthe yaw axis. In FIG. 6 a rocker style sensor assembly 158 includes aT-shaped member and having a vertical center arm 160 engaged within agroove in the underside of collet 16, and the T-shaped member beingpivotally supported at a lower center so that the two oppositelydisposed lateral arms 162 may be pivotally moved up and down dependentupon the direction of rotation of the collet to interact with adirection indicating negative sensor 164 and a direction indicatingpositive sensor 166 shown mounted on lower member 20. The negative andpositive sensors 164, 166 may be simple on/off switches, or may be moresophisticated sensors which indicate degree or pressure in addition tothe direction collet 16 has been rotated, such as by varying voltage viaresistance changes, or by varying electrical output such as with piezoelectric material and the like. When a rotatable collet is used, asensor is used to detect rotation of collet 16 as described above, butthis does not bar still having a sensor (encoder) in communication withtrackball 12 for detecting rotation of the trackball about the yaw axis,and this would give the user the option of rotating about yaw via thetrackball or the rotatable collet. Further, the trackball 12 inputmember may be interpretable on all six axes as previously described, andthe rotatable collet can serve as an additional secondary input memberfor whatever use may be desired by a software designer or end-user.

I prefer most all of the circuits, switches and sensors be mounted oncarriage 14, and more particularly the lower member 20, which is a sheetmember, and this being an advantage for maintaining low cost inmanufacturing. Dependent upon the type and sophistication of the sensorsutilized in the present controller, and the electronics and/or softwareand electronics of the host graphics image generation device which thepresent invention is intended to interface, and at least in partcontrol, there may be little more than flexible electrical conductorsconnected to on/off switches mounted on the lower member 20, with theflexible conductors leaving the lower member to exit housing 10 via acord 156 connectable to the host image generation device, or leavingcircuitry on lower member 20 to connect to an emitter of electromagneticradiation (not shown) mounted on housing 10 for communicating the linearmoment and rotational information with the host device via wirelesscommunication such as via infra red light or radio signals. Lower member20 may be a printed circuit board having sensors, integrated and ordiscrete electronic components thereon, and in FIG. 2 an applicationspecific integrated circuit chip is illustrated at 130 which could beutilized for computations, encoding, memory, signal translations such asanalog to digital conversions, data formatting for communication to thehost device, serial and/or parallel communications interfacing, and thelike steps or processes. The specific circuitry and electronics builtonto or into the present invention will in all likelihood be differentwhen the invention is built primarily for use with a personal desk topcomputer than when it is built primarily for use with an interactivetelevision or television based electronic game for example. Any requiredelectrical power for electronics or sensors or output signals may beprovided by batteries within housing 10, or via a connected cord or anyother suitable power source. A combination of electrical power inputsmay be used, and this would depend on the particular application forwhich the controller was designed.

As previously mentioned, housing 10 may be in numerous forms, forexample, FIG. 8 is an illustration of housing 10 structured specificallyfor carriage 14 and trackball 12, and one which is structured to restupon a support surface such as a table or desk when utilized, and thisunit may be used to replace a typical mouse used with a computer. Anoptional extending portion 142 is shown indicated in dotted outline, andwhich is ergonomically designed as a wrist and forearm rest. Theembodiment shown in FIG. 8 is also shown with two thumb select switches144 and two finger select switches 146 (secondary input members) whichmay be included to be used as function select switches as is common on atrackball, mouse or joy stick. A further example of a useful housing 10is shown in FIG. 9 wherein a hand held housing 10 sized and shaped to begrasped in a hand of a user while the user controls graphic images withthe controller in accordance with the present invention is shown. This“remote control” style version of the invention may be direct wired withlong flexible conductors to the host graphic image generation device(computer or television for example), but is preferably a wirelessremote controller which sends information to the graphics generationdevice via wireless electromagnetic radiation indicated at 138. The FIG.9 remote control is battery powered with a battery in compartment 134,and may include a scan or program window shown at 132 for allowingprogramming of internal electronics. This version may prove to beparticularly useful with interactive television and interactivethree-dimensional displays such as are commonly referred to as virtualreality displays, and most likely will include additional function keys136 for on/off, volume, channel selection, special functions and thelike.

FIG. 10 shows carriage 14 and trackball 12 (embodiment 9) housed in anotherwise relatively conventional computer keyboard 140. Embodiment 9 isshown replacing the arrow-keypad, although is can be incorporated intoother areas of the keyboard 140. Embodiments 172 and 200, to bedisclosed, can also be incorporated into a computer or like keyboard,and as will become appreciated.

FIG. 11 represents a desk top computer 148 as an example of a graphicimage generation device, and shown on the display 150 (computer monitor)is a cube 152 displayed three dimensionally. An electromagnetic signalreceiver window is shown at 154 for receiving signals such as are sentvia a wireless communicating version of the present invention such asthat shown in FIG. 9. Alternatively the keyboard 140 of FIG. 10 could beconnected to the host image generation device via flexible conductor set156 to allow typical keyboarding when desired, and control of graphicimages with the use of the present six degree of freedom controller whendesired.

With reference now to FIG. 12, wherein a partial cross-sectional endview of a joystick type embodiment 172 of the invention is shown.Embodiment 172 is or can be structured identically to the FIGS. 1-3trackball embodiment, with the exception of an elongated graspablehandle 174 engaged, by any suitable connecting arrangement on an exposedportion of the ball 12, such as by integral molding or casting, orconnecting with adhesives or screws, etc. Full 6 DOF is provided withembodiment 172, as the user grasps handle 174 and can control carriage14 and ball 12 with linear and rotational forces applied to handle 174.The input member in embodiment 172 is considered handle 174, and thereference member is considered housing 10. Embodiment 172 can includehousings in numerous shapes and sizes such as the housing 10 shown inFIGS. 8, 9 and 10 for example.

At this point in the description, it is believed those skilled in theart can build and use at least one embodiment of the invention, andfurther can build and use a trackball type and a joystick typeembodiment in accordance with the present invention without having toresort to undue experimentation, however further joystick typeembodiments in accordance with the present invention will be describedto further exemplify the broad scope of the invention.

FIGS. 13-21 show variations on a joystick-type embodiment 200 which is ahand operated 6 DOF physical/mechanical to electrical converter forimage control which has all 6 axes bi-directionally mechanicallyresolved in a pure fashion to the respective individual sensorsrepresenting each axis. Further embodiment 200 teaches all necessarysensors located within a handle 202. Embodiment 200 further teachesstructuring enabling the possible location upon a single sheet of allnecessary sensors for a 6 DOF controller device.

FIG. 13 shows an exploded view of joystick embodiment 200 of the currentinvention exhibiting structuring enabling use of a membrane sensor sheet206. All 6 DOF operations of the input member shown as joystick-typehandle 202 (comprised of upper handle part 202.2 and lower handle part202.1) relative to the reference member shown as shaft 204 aretranslated to specific locations on membrane sensor sheet 206.

Shown at the bottom of the drawing is shaft 204 which may or may not bemounted to many different base-type or other structures. Shaft 204 isshown as generally cylindrical and substantially aligned, for purposesof description, along the yaw axis. Shaft 204 is substantially hollow toallow passage of the membrane tail, wiring or electrically connectingmaterial, and is made of a generally rigid and strong material such asinjection molded acetal plastics or steel etc. Shaft 204 has fixed toone end a short extending pedestal 210 and fixed to pedestal 210 ispivot ball 208. Shaft 204 also has a yaw slide-rail 212. Slide-rail 212is a component that serves to keep translator 214 from rotating relativeto shaft 204 about the yaw axis while still allowing translator 214 tomove vertically along the yaw axis. One skilled in the art will readilyrecognize variants in the specifically drawn and described structureafter reading this disclosure. For example, slide rail 212 would not benecessary if shaft 204 were square shaped rather than cylindricallyshaped.

Substantially surrounding but not directly connected to shaft 204 is alower handle part 202.1 which is made of a substantially rigid materialand is shown having a round short vertical outer wall and essentiallyflat bottom with a central large round cut out area to allow formovement of handle 202 relative to shaft 204. Lower handle part 202.1 isfixed, preferably by screws, to upper handle part 202.2 thus the twoparts in unity form handle 202 which encompasses all the remaining partsof this embodiment. The flat bottom of lower handle part 202.1 isslidable horizontally along the pitch and roll axes relative to theessentially flat underside area of a first carriage member 216. Firstcarriage member 216 has centrally disposed an aperture which is shownwith edges forming a planar cut of a female spherical section which isrotatably slidably mated to a male spherical section of translator 214.Translator 214 has a vertical female cylindrical aperture and yaw sliderail slot 213 to mate with shaft 204 as previously described. Translator214 additionally has at its upper edge two oppositely disposed anti-yawtabs 218 which lay essentially in a horizontal plane described by thepitch and roll axes. Anti-yaw tabs 218 fit within substantially verticalslots formed by rising posts 220 which are fixed to and preferably moldintegrally with carriage member 216. The functional result of anti-yawtabs 218 working within the slots and the mating of the male sphericalsection of translator 214 with the female spherical section of carriagemember 216 creates the mechanical result that while translator 218 isheld substantially non rotatable relative to shaft 204, carriage member216 is rotatable about the pitch and roll axes but not the yaw axisrelative to both translator 214 and the general reference member shaft204. Rising posts 220 fixedly connect first carriage member by screws,snap fit connectors, or other connecting means to a second carriagemember 222 which may in some variations of this embodiment be a circuitboard sheet supporting all necessary sensors, but as shown in theembodiment of FIG. 13 support sheet allows a formative and supportivebacking for membrane sensor sheet 206. Second carriage member 222 ismade of a rigid material such as, for example, injection molded acetalplastic and is shown in FIG. 13 as being essentially a flat circularplate with a circular cut out at its center and with six downwardlyextending plate like structures (as shown) which serve as back supportsfor sensors located on flexible sensor membrane 206 which is bent orflexed (as shown) at appropriate locations to allow sensors to bepositioned correctly between the second carriage member and theactivating part for each individual sensor.

In association with the sensors, in a preferred embodiment, areresilient “tactile” return-to-center parts 226 (herein after “tactileRTCs 226”) which are shown in FIG. 13 as rubber dome cap typeactivators. These tactile RTCs 226 are positioned between sensors andactivating mechanical hardware so that when the input member is operateda specific piece of activating mechanical hardware, member, or part(which specific activating part depends on which specific sensor isbeing described) moves to impinge on the local tactile RTC 226 andcompresses it. As the impinging/compressing force grows a force“break-over” threshold, inherent in the tactile RTC 226, is overcome andthe force rapidly but temporarily decreases and the sensor is impingedand activated. This break-over tactile threshold can be achieved withnumerous simple tactile structures, such as the rubber dome capstructures illustrated as RTCs 226 in FIG. 13, or metallic dome capstructures (which give an exceptionally strong clear feedback sensation)and other more complex spring based break over structures. Theseresilient break-over structures are typically used in the industry forsimple on-off switches, such as the audible and tactile break-overswitches commonly used to turn on and off lights in the home, and in theoperation of typical computer keyboard keys.

I believe that my structuring enabling the use of this common break-overtechnology in a 6 DOF controller is a highly novel and usefulimprovement in the field of 3D graphic image controllers. Further, itcan clearly be seen here, after study of this disclosure, that tactilebreak-over devices can also be used to great advantage in novelcombination with proportional or variable sensors within my mechanicallyresolved 6 DOF controller structurings, and that this is a novel andvery useful structure.

The resilient components RTCs 226, when compressed, are energized withintheir internal molecular structure, to return to the uncompressed state,thus when the user takes his hand off of the input member, or relaxesthe force input to the input member then the resilient RTCs 226 push themechanical parts of the controller back off of the sensor and toward acentral null position of the input member. RTCs 226 serve to greatadvantage on all six axes in most joystick type controllers and on thethree linear axes in the trackball type controller.

Positioned to activate sensors 207.03 through 207.06, as shown in FIGS.14 and 15, are sliding actuators which are impinged upon by the insidesurface of the outer wall of handle 202.

Above member 222 is a yaw translator plate 230 with an oblong centralcut out (as shown) and distending plate-like members are two oppositelydisposed yaw activators 231 which extend, when assembled, down throughthe illustrated slots of member 222 to activate sensors 207.07 and207.08 when handle 202 is rotated back and forth about the yaw axis.

On the upper surface of plate 230 are fixed or integrally molded pitchslide rails 232 which are oriented substantially parallel to the linearcomponent of the pitch axis, and fit into and slide within femalecomplementary pitch slide slots 234 which are molded into the undersideof anti-rotating plate 236 which is located above plate 230 andsandwiched between plate 230 and upper handle part 202.2. Anti-rotatingplate 236 is a plate like structure with an oblong-shaped central cutoutand on the upper surface are molded roll slide slots 238 which aresubstantially aligned with the linear component of the roll axis andthrough which slide roll slide rails 240 which are integrally molded onthe inside surface of upper handle part 202.2.

Within the assembled embodiment 200 located at the approximate center ofhandle 202 is pivot ball 208 which is fixed to shaft 204. Pivot ball 208is immediately surrounded on top and sides by the recess within a linearyaw axis translator 242 which is a substantially rigid structure havingan oblong-shaped horizontally protruding upper activating arm 244 (asshown) and on its lower portion are snap-fit feet 246 or other attachingmeans or structures for fixing a lower activating arm 248 to the bottomof translator 242, thus pivot ball 208 becomes trapped within the recesswithin translator 242 by the attachment of lower activating arm 248forming a classic ball in socket joint, wherein translator 242 is freeto rotate about ball 208 on all rotational axes but not free to movealong any linear axis relative to ball 208 and shaft 204.

FIG. 14 shows membrane sensor sheet 206 in flat form as it would appearafter being printed with conductive pads for sensors 207 and conductivecircuit traces 256 but prior to being cut from sheet stock along cutline 254.

FIG. 15 shows a larger clearer view of membrane 206 and second carriagemember 222, with membrane 206 in the folded configuration as it wouldfit on the membrane support sheet 222 and the rubber dome cap tactileresilient activators 226 where they would rest upon membrane 206 eachone above a sensor 207.

FIG. 16 shows all sensors 207 in mechanical packages having solder tangsthat are solder mounted to the second carriage member, which in thiscase, specifically, is a rigid circuit board sheet 250. Sensors 207.01through 207.12 are positioned essentially in the same locations asindicated in FIGS. 13 and 14. The different sensor sheet technologiesare shown to be interchangeable within the novel structuring of theinvention. Substituting circuit board 250 into the embodiment shown inFIG. 13 replaces the parts shown in FIG. 15, specifically, membrane 206,second carriage member 222, sliding actuators 228 and rubber dome caps226 can all be replaced by the structure of FIG. 16.

Whether on membrane sheet 206 or circuit board 250 specific sensors 207are activated by the following movements and rotations with therespective structures described here:

-   linear input along the yaw axis in the positive direction (move up)    causes sensor 207.01 to be activated by upper activating arm 244,-   linear input along the yaw axis in the negative direction (move    down) causes sensor 207.02 to be activated by lower activating arm    248,-   linear input along the roll axis in the positive direction (move    forward) causes sensor 207.03 to be activated by the inner surface    of the outer wall of handle 202, (with rubber dome cap 226 and slide    228 on membrane variation),-   linear input along the roll axis in the negative direction (move    back) causes sensor 207.04 to be activated by the inner surface of    the outer wall of handle 202, (with rubber dome cap 226 and slide    228 on membrane variation),-   linear input along the pitch axis in the positive direction (move    right) causes sensor 207.05, to be activated by the inner surface of    the outer wall of handle 202, (with rubber dome cap 226 and slide    228 on membrane variation),-   linear input along the pitch axis in the negative direction (move    left) causes sensor 207.06, to be activated by the inner surface of    the outer wall of handle 202, (with rubber dome cap 226 and slide    228 on membrane variation),-   rotational input about the yaw axis in the positive direction (turn    right) causes sensor 207.07 to be activated by yaw activator 231,-   rotational input about the yaw axis in the negative direction (turn    left) causes sensor 207.08, to be activated by yaw activator 231,-   rotational input about the roll axis in the positive direction (roll    right) causes sensor 207.09 to be activated by the top edge of    translator 214,-   rotational input about the roll axis in the negative direction (roll    left) causes sensor 207.10 to be activated by the top edge of    translator 214,-   rotational input about the pitch axis in the positive direction    (look down) causes sensor 207.11 to be activated by the top edge of    translator 214,-   rotational input about the pitch axis in the negative direction    (look down) causes sensor 208.12 to be activated by the top edge of    translator 214.

FIG. 17 shows membrane 206 in a variation where all 6 DOF sensors 207are positioned on a flexible membrane sensor sheet and positioned on asingle flat plane. All sensors are activated by structuring acting onmembrane 206 from the lower side as membrane 206 is pressed up againstthe second carriage member 222, except for sensor 207.01 which isactivated by structure from above pressing sensor 207.01 down against arecessed support shelf 258 which is integrally molded as part of platemember 222. Shelf 258 is molded in such a way as to leave at least oneside, and as drawn two sides, open so that sensor 207.01 can be slidthrough the open side during assembly to rest on recessed support shelf258. Sensor 207.01 having a cut-out 260 near at least two edges ofsensor 207.01 thus allowing positioning of membrane 206 with all sensors207 on an essentially single plane. Sensors 207.03 through 207.08 whichwere flexed into right angle positioning in the variation of FIGS. 13-15are now all on the same plane and each is impinged upon and activated byright angle translation structuring shown as a rocker-arm activator 262which pivots on an integrally molded cylindrically shaped fulcrum 264which is held in position by saddle shaped upward protrusions 266 fixedto first carriage member 216 and saddle shaped downward protrusions 268fixed to second carriage member 222. This right angle translationstructuring works as follows: For example, if input member handle 202 ispressed to move along the roll axis in a positive manner then aflattened area along the inside surface of the outer wall of handle 202impinges upon the lower portion of rocker-arm activator 262 causingactivator 262 to pivot about fulcrum 264 and the upper part of activator262 impinges upon tactile resilient activator 226 (shown here as ametallic dome cap) until sufficient force has built to allow tactileactuator 226 to “snap through” and come to bear upon and activate sensor207.03. These structures do not have to have “snap through” or tactileturn-on resilient structuring to be fully functional, but this tactileturn-on resilient structuring is believed to be novel in 6 DOFcontrollers and highly advantageous in the feedback it offers to theuser.

FIG. 18 shows structuring of membrane 206, as described in FIG. 17,integrated into an otherwise typical computer keyboard membrane 270 byconnection of membrane tail 224 to keyboard membrane 270 (which may bestructured of the common three layer membrane structuring, or singlelayer membrane structuring, or any other type). In this embodiment shaft204 is fixed to keyboard housing 10 (shown in FIG. 19) and for assemblymembrane 206 is rolled up and inserted through shaft 204 and thenunrolled where it is positioned against member 222.

FIG. 19 shows an external view of a 6 DOF handle 202 positioned wherethe arrow key pad would be on an otherwise common computer keyboardhousing 10. With the current structuring many different positionings ofa 6 DOF handle on a keyboard are possible, such as positioning handle202 in the area normally occupied by the numeric keypad, or on anergonomically designed keyboard having the large key bank of primarilyalphabetic keys divided into two banks angled apart positioning ofhandle 202 between the two alphabetic key banks is a distinctpossibility, etc. Further, in the common keyboard the 6 DOF operationscan or cannot emulate keys such as the arrow keys when handle 202 isoperated appropriately. An optimum keyboard may have proportionalsensors built into the membrane and output both proportional and simpleswitched data. For example, an optimum keyboard may sense a certainhandle 202 movement and send out both a scan code value representing anappropriate key stroke (such as an arrow key value) and the keyboard mayalso output a proportional value representing how intense the inputoperation is being made.

FIGS. 20-31 show another preferred embodiment exhibiting two planarstructuring. Two planar design offers some advantages. Such a devicestill has all the benefits of a pure mechanically resolved device andwith two planar execution additional benefits are realized, such as: thecapability of exceptionally low profile design for integration intocomputer keyboards and hand held remote controllers, ready integrationof finger operated buttons on the handle for operating sensorsincorporated into the sensor sheet, space to place active tactilefeedback means in a still small handle, etc. An example of an activetactile feedback means is an electric motor with shaft and offset weightwithin a handle for providing active tactile feedback, as shown indrawing FIG. 21.

Referring to FIG. 20, an input member which is shown as a handmanipulatable handle 300 is shown supported on a shaft 302. Shaft 302extends into a base or reference member housing 317. Shaft 302 passesthrough a shaft guide first main hole 306 within a sliding plate orplatform called a first platform 352. Shaft 302 further passes through ashaft guide second main hole 310 located in a second platform 322. FIG.21 shows Platform 322 fixedly attached to connecting structure shown aslegs 312 which are fixed to first platform 352, thus platform 322,connecting structure 312 and platform 352 cooperate together forming thestructure of a carriage 314.

First platform 352 is slidably retained along a first axis by a slidingplate called an anti-rotating plate 350 which is slidably retained alonga second axis by at least one housing guide 308 which is fixed tohousing 317. First platform 352 and plate 350 are further constrained byretaining shelf 316 and housing 317 from linear movement along the yawor third axis. Thus plate 350, guide 308, housing 317, and shelf 316cooperate to form a carriage support structure 316 in which platform 352(and thus also carriage 314) is prohibited from significantly rotatingon any axis, and also is allowed to linearly move significantly alongthe first and second axes (pitch and roll axes) but is prohibited fromsignificant movement along the third axis, relative to housing 317.

Within carriage 314, and platforms 352, 322, holes 306 and 310 cooperateto offer sufficient fit in the passage of shaft 302 to provideadvantageous structural cooperation in two substantial ways. The firstis the provision of an anti-tilting structure 324 which prevents shaft302 from significant tilting (rotating about the first or second axes)relative to carriage 314. The second is provision of two-axes structurewhere any and all linear movement along parallel to the first and secondaxes (linear along length of pitch and roll axes) by shaft 302 iscoupled to equivalent movement along parallel to the first and secondaxes of carriage 314.

A second endward region of shaft 302 as shown in FIG. 21 is shaped witha male partial spherical shape 318 which slideably contacts acomplimentary female partial spherical shape 319 which is part of handle300, and shaft 302 also comprises a male pivot protrusion having a pivotor rotational point located approximately central to handle 300 andapproximately at the center of the spherical partial section shapes.Protrusion 346 provides a pivot point for handle 300 and may mate to afemale pivot receptacle. Thus handle 300 can be rotational relative toshaft 302 yet coupled for all linear movement along parallel to thefirst and second axes with equivalent linear movement of shaft 302 andalso two-axes structure 326, therefore the above mentioned membersconnecting handle 300 to shaft 302, and shaft 302 to carriage 314 serveas a handle support structure 328 in which handle 300 is coupled forequivalent movement with carriage 314 along parallel to the first andsecond axes.

On carriage 314 are rocker-arm structures 364 shown mounted on secondplatform 322. Rocker-arm structures 364 convert movement of carriage 314relative to housing 317 to a resilient thermoplastic rubber (TPR) sheet366 formed with a plurality of “tactile” resilient dome cap structures368. Resilient sheet 366 and second platform 322 sandwich sensorssupported on a membrane sensor sheet 330.

FIG. 22 shows the positioning of four rocker-arm structures 364 as theyare mounted on second carriage part 322 which is shown as asubstantially flat plate that might be manufactured as a traditionalprinted circuit board sheet bearing on-board sensors and containingon-board active electronic circuitry 370 and a cable 372 for routingdata to a graphics display device, or as a flat rigid plate-likestructure supporting a flexible membrane sensor sheet 330. Shown on topof and essentially parallel to plate 322 is rubber sheet 366 having amultiplicity of tactile resilient rubber dome cap type actuators 368.

Rocker-arm structures 364 have at least the following structure: amounting structure 332, which is structure essentially fixed to carriage314 and is illustrated as a snap-fit design having two legs which snapinto slots within plate 322; a fulcrum 334, illustrated in all figuresas a living hinge located at the top of mounting structure 332 except inFIG. 24 where fulcrum 334 is illustrated as a more traditionalcylindrical bore-and-core type hinge; at least one sensor actuating arm336, and in all drawings rocker-arm structures 364 are illustrated ascommonly having two arms for actuating two sensors one on each side ofmount 332, except in drawings 26 and 27 where are illustrated one-armedvariants; and finally rocker-arm structures 364 have a super-structure338 by which the rocker-arm is activated or caused to move against andactuate the associated sensor(s). Super-structure 338 is the distinctivepart of the different two armed rocker-arm types shown in FIGS. 20-22,of which are a V-slot type 340, an H-slot type 342, and a T-bone type345 of which there are two rocker-arms being approximately identical butoriented perpendicular to one another and being called a first t-bone344 and a second t-bone 364 rocker-arm actuators.

FIG. 23 shows T-bone actuator 345 mounted to plate 322 by mountingstructure 352 and pivoting (shown actuating sensor in dashed lines)about fulcrum 334 shown as a living hinge which is connected to thebottom of two oppositely disposed actuating arms 336 above which isfixed super-structure 338 which is activated into motion by a activatingreceptacle 339 that is fixed to the reference member base or housing 10by way of retaining shelf 316. Under the opposite side of actuator 345from dome cap 368 (which is shown in dashed lines as being depressed andthus actuating sensor 207 located on flexible membrane sensor sheet 330)is illustrated a packaged mechanical sensor 207 soldered to a flatcircuit board sheet. Thus, FIGS. 22 and 23 clearly show how the sameinventive structurings can translate mechanical or physical inputs toeither a flexible membrane sensor sheet or to a rigid circuit boardsensor sheet.

FIG. 24 shows H-slot actuator 342 as it is activated by shaft pin 321which is fixed within shaft 302. As shaft 302 moves vertically or alongthe yaw or third axis then so in unison moves shaft pin 321 and actuator342.

A first end of shaft pin 321 passes through a beveled slot within superstructure 338 of rocker-arm H-slot type 342 in which the slot isapproximately perpendicular to the third axis and the length of shaft302, so that when shaft 302 and shaft pin 321 move along the third axisrocker-arm 342 in moved in kind with one arm descending to compress itsrespective resilient dome cap 328 and upon collapse of dome cap 328 therespective underlying sensor is actuated, as shown in FIG. 24. Of coursemovement of shaft 302 in the opposite direction along the third axislikewise actuates the opposite complimentary sensor of the sensor pair.Rotation within operational limits of shaft 302 about its cylindricalcenter or approximately about the third axis simply causes shaft pin 321to move within the slot and does not activate the H-type rocker-arm 342.

FIG. 25 shows activation of V-slot actuator 340. A second end of shaftpin 321 passes through a slot of V-slot rocker-arm 340 which isactivated in the converse of the above H-slot rocker arm 342. Movementof shaft 302 along the third or yaw axis simply causes shaft pin 321 tomove within the slot and not actuate V-type rocker-arm 340, but rotationabout the third axis causes shaft pin 321 to activate rocker-arm 340 inthe following manner. Rotational motion of shaft 302 conveyed to shaftpin 321 activates rocker-arm 340 causing compression of dome cap 328 andstimulation of the sensor located on the membrane. Super structure 338of rocker-arm 340 has a slot in structure slanting away from shaft 302.This is to accommodate the increasing movement of pin 321 as it maychange in distance from fulcrum 334 when shaft 302 is moved along thethird axis. Thus the slope of the slot compensates for varyingeffectiveness of shaft pin 321 so that rotation of shaft about the thirdaxis causes rotationally equivalent activation of rocker-arm 340regardless of the distance shaft pin 321 is from fulcrum 334 ofrocker-arm 340.

FIGS. 26 and 27 show space savings structuring for the area of secondplatform 322. This space savings may be valuable in tightly constrictedareas such as integration of the invention into computer keyboards andhand held remote control devices. The layout of second platform 322 asillustrated in FIGS. 20-22 is shown by a dashed line indicating theoriginal larger perimeter 371 the area of the newer smaller platform 322shown by solid line 372 and first t-bone rocker-arm 346 has been dividedinto two separate one-armed type 348 actuators each with its own mount332, fulcrum 334, sensor actuating arm 336, and super structure 338.

FIG. 28 shows structuring within handle 300 for support and activationof sensors 207 supported on sensor membrane sheet 330 which may besupported within the inside upper portion of handle 300 or as shown heresupported by a rigid support sheet 374 the appendage of membrane 330passes through shaft 302. Also shown here are two buttons 378 foroperation by the user's fingers. Buttons 378 have an exterior activatingsurface area 378 which can be depressed by the user's finger(s) causingbutton structure 376 to rotate about an integrated cylindrical fulcrum380 which rests within saddle supports fixed to handle 300. The pivotingmotion of button 376 causes the internal sensor actuating part 382 torise against resilient dome cap 368 and activate sensor(s) 384. Thisbutton structuring is similar to that shown in FIG. 17 with theexception that the structuring of FIG. 17 is completely internal whilethis design has the button externally operated for additional input(other than 6 DOF input) by the user's finger(s).

FIG. 29 shows a sensor membrane 330 of a three layer traditionalcomputer keyboard type, but with the inventive exception of having twoadditional appendages designed for fitting into the two planar structuredesign shown in FIGS. 20-28 for incorporation in a keyboard as shown inFIG. 19. The appendage having the longer attachment and a rounded headpasses from inside the keyboard housing 10 up through the shaft and intothe handle and the other appendage resides on carriage part 322 withinhousing 10.

FIG. 30 shows 6 DOF input member handle 300 integrated with shaft 302fixed to housing 10 of an otherwise normal wireless remote controldevice, such as for operating a television, or other device, etc.

FIG. 31 shows the device of FIG. 30 in dashed lines showing an internalview of a likely form for membrane sensor sheet 330. Membrane sheet 330is shown connected to a circuit board sensor sheet 250 that commonly ispositioned under the normal input keys and also contains electroniccircuitry. Membrane tail 224 connects from sheet 250 to the greater bodyof membrane 330 which in this case is shown as a two planar type asshown in FIGS. 20-28. This arrangement of sensors on two planes is quiteideal for many uses. It allows the origin of all axes to remain withinhandle 300 and yet much of the mechanical resolving structure is moveddown into housing 10 where space is more plentiful, thus handle 300 canbe made even smaller and even lower in profile, if desired.Additionally, auxiliary secondary input buttons (select, fire buttons,special function keys, etc.) are readily integrated in an economical andrugged fashion for operation by the user's finger(s).

FIGS. 33-35 show a preferred embodiment of the two planar design withoutusing rocker arms and having packaged sensors 207 shown here as simplemechanical flat-mount and right-angle-mount switch packages, mounted onsecond carriage part 322 which, in this embodiment, is a circuit boardto which the sensor packages are soldered, and also the sensor packagesare solder mounted on a second circuit board 423 within handle 400. Thisembodiment has some parts and structures that are similar to equivalentparts in earlier embodiments such as a hand operable input member shownas a handle 400 supported on a shaft 402 which extends into a housingwhich serves as a reference member or base 417 where it interfaces withcarriage 414. Carriage 414 is supported by a similar carriage supportstructuring and carriage 414 has platform 352 with distending legs 112which connect to second carriage part 422 which, in this embodiment, isspecifically a circuit board carrying eight sensors for interpretationof four axes.

Specifically shown in FIG. 33 is a 3rd axis actuator part 450 which hasa specific structuring that allows all sensor mountings on the circuitboard to be fully functional with flat and right-angle-mount mechanicalsensor packages. Actuator part 450 is integrated to the end of shaft 402that is in communication with carriage 414. Actuator 450 may beintegrated with shaft 402 as a single, injection-molded part or actuatorpart 400 may be a separate molded part fit over the end of shaft 402 andsecured to shaft 402 by a pin 452 passing through both shaft 402 andactuator part 450. Actuator part 450 has at least a 3rd axis rotationalactuator 454 which is a plate-like member fixed to actuator part 450 andextending outward in a plane having substantially the 3rd (yaw) axis asa member of that plane so that when shaft 402 rotates in eitherdirection about the 3rd axis, actuator part 454 moves through space,actuating the appropriate right-angle-mount sensors indicating a 3rdaxis rotational movement in either the positive or negative direction.Actuator part 450 has a 3rd axis negative (yaw—move down) linearactuator 458 and a 3rd axis positive (yaw—move up) linear actuator 456which also are fixed to actuator part 450 and extend outward from part450 perpendicular to the 3rd axis and substantially aligned with a planeparallel to the 1st and 2nd axes, so that when shaft 402 moves along the3rd axis in a positive direction, actuator 456 activates the appropriateflat mount sensor indicating linear movement along the 3rd axis in apositive direction, and when shaft 402 moves along the 3rd axis in anegative direction, actuator 458 activates the appropriate flat mountsensor indicating linear movement along the 3rd axis in a negativedirection.

FIG. 36 shows a final preferred embodiment having some similarstructures to earlier embodiments, especially those shown in FIGS.32-35, with the primary exception that in this embodiment eight sensorsare located within the hand operable input member handle 500 and onlyfour sensors are located within the reference member housing 517. Inthis embodiment a similar carriage 514 is located within housing 517 butshaft 502 is fixed to plate 552 of carriage 514 so that shaft 502 isfree to move only linearly within a plane perpendicular to the 3rd (yaw)axis. A part shaped almost identically to part 450 is fixed at the topof shaft 502. Sensors 207 within handle 500 are mounted to circuit board523.

In the interest of brevity, it is appreciated that after study of theearlier embodiments one skilled in the art will be able to easilyconstruct the full structuring of the embodiment of FIG. 36 from thisfull illustration without an overly extensive written description.

FIG. 37 shows a right angle simple switched sensor package as iscommonly available in the industry. It is comprised of a non-conductiverigid plastic body 600 supported by electrically conductive soldermounting tangs 606 and 608 which are typically made of metal.Electrically conductive tang 606 passes from the exterior of body 600 tothe interior where it resides in a generally peripheral position of aninternal cavity of body 600, and electrically conductive tang 608 passesfrom the exterior of body 600 to the interior where it resides in agenerally central position of the internal cavity. Positioned over theinternal portions of tangs 606 and 608 is a metallic dome cap 604 havingresilient momentary “snap-through” characteristics. Metallic dome cap604 typically resides in electrical contact with tang 606 on theperiphery and typically not in contact with centrally positioned tang608. Positioned to depress dome cap 604 is a plunger 602 which isgenerally made on non-conductive rigid plastic material. Dome cap 604and plunger 602 are typically held in place by a thin metallic plate 610which is fixed to body 600 by plastic melt riveting or other means.Plate 610 has an aperture large enough for a portion of plunger 602 toprotrude to pressed upon by an outside force and thus to depressconductive dome cap past a tactile snap-through threshold and down ontocentrally disposed conductive tang 608, thus completing an electricallyclosed circuit between tangs 606 and 608.

FIG. 38 shows an even more typical sensor package body 600 in that it ishorizontally mounted, which is the most common style. But the sensor ofFIG. 38 has an additional very important element. In the inner cavity ofbody 600 and fixed above, and electrically in connection with, centrallypositioned conductive tang 608 is a pressure sensitive electricalelement 612, which may have a conductive metallic plate 614 fixed to theupper surface of element 612 for optimal operation. Of course, this samedesign can be integrated into the sensor of FIG. 37. Pressure element612 is constructed of a pressure sensitive material, such as forexample, molybdenum disulfide granules of approximately 600 grit sizemixed with a base material such as silicon rubber in, respectively, an80-20 as taught in U.S. Pat. No. 3,806,471 issued to inventor Robert J.Mitchell on Apr. 23, 1974, ratio, or other pressure sensitiveelectrically regulating materials. I believe that integration ofpressure sensitive technology into a tactile-snap through sensor packageis novel and of great advantage in 6 DOF controllers as shown herein anddescribed in my earlier 6 DOF controller patent applications.

FIGS. 39 and 40 show cross-section views, respectively, of anon-actuated and an actuated flexible planar three layer membranecomprised of an upper electrically non-conductive membrane layer 620, amid electrically non-conductive membrane layer 622 and a lowerelectrically non-conductive membrane layer 624 all positionedessentially parallel to each other with upper layer 620 having anelectrically conductive trace 626 on its lower side and lower layer 624having an electrically conductive trace 628 on its upper side with midlayer 622 normally isolating the traces except in the central switchingor sensing region where mid layer 622 has an aperture. In a traditionalthree layer flexible membrane sensor the aperture in mid layer 622 isempty allowing upper layer 620 to be depressed flexing down untilelectrically conductive trace 626 comes into contact with electricallyconductive trace 628 of lower layer 624 and completes an electricalconnection, as is commonly known in the prior art. The membrane layersare supported upon a generally rigid membrane support structure 630 suchas a rigid plastic backing plate.

The membrane sensor shown is novel with the inclusion of apressure-sensitive electrically regulating element 638 disposed in thesensing region, filling the traditionally empty aperture of mid layer622. Pressure element 638 remains in electrical contact with broadconductive areas of conductive traces 626 and 628 at all times. Pressureelement 638 may be of a type having ohmic or rectifying granularmaterials (such as 600 grit molybdenum disulfide granules 80-98%) in abuffering base matter (such as silicon rubber 2-20%) as described inU.S. Pat. No. 3,806,471 issued to inventor Robert J. Mitchell on Apr.23, 1974, or other pressure sensitive electrically regulating technologyas may exist and is capable of being integrated with membrane sheettechnology.

Also I believe it is novel to use a metallic “snap-through” resilientdome cap 632 with for its excellent tactile turn-on feel properties incombination with membrane sensors and especially with membrane pressuresensors as shown, where metallic dome cap 632 resides on top of uppermembrane layer 620 and is shown held in place by silicon adhesive 636adhering dome cap 632 to any generic actuator 634. Generic actuator 634may be the actuating surface area of any part which brings pressure tobear for activation of a sensor, for example, actuator 634 might be anipple shaped protrusion on the underside of rocker arm actuator arms336 on the embodiment of FIGS. 20-31, etc. Vibration lines 640 indicatean energetic vibration emanating outward either through support 630 oractuator 634 as a mechanical vibration transmitted through the connectedparts to the user's hand, or as air vibrations perceived by the user'sear, and indicating the “snap-through” turn-on/off sensation ofresilient dome cap 632 as it impinges upon and activates the sensor.With twelve possible singular input operations, and a very large numberof combined input operations the user perceivable tactile sensationindicating sensor activation is of high value to the operator of thedevice.

FIG. 41 shows a compound membrane sensor sheet 700 containing amultiple-layer staged sensor 701. Staged sensor 701 is comprised bylayering, one on top of the other, more than one traditional simplemembrane switch and sharing layering which can be used in common. Forexample, the top layer of the lower sensor and the bottom layer of thetop sensor can be combined using both sides of the common layer to fullavail, thus two three layer sensors are combined into one five layersensor, etc. Staged sensor 701 can be useful in measuring increasedactivating force of the impinging activator coming down on sensor 701from above with sufficient force first activates the upper sensor andwith sufficient additional force then activates the second sensor, andso on. Many layered sensors are possible.

FIG. 42 shows a compound membrane sensor sheet 700 containing a compoundsensor 702 which in essence is a commonly known simple switched membranesensor on top of my novel proportional membrane sensor as described inthe embodiment of FIGS. 39 and 40, with the two respective sensorssharing the middle sheet so that two three sheet sensors are combinedinto one five sheet sensor. In combination with earlier drawings anddescriptions herein, and the commonly known prior art the compoundsensor shown here becomes self descriptive to one skilled in the art.

Some commonly known simple switched sensors use only a single sheetrather than three sheets, with the single sheet having both conductivetraces sharing one surface area and the resilient dome cap having aconductive element which when depressed connects the conductive traces.One skilled in the art will also appreciate that the novel compoundsensor 702 may be made with less than five sheets using such technologyand judicious routing of conductive traces.

Both the simple switched portion and the proportional portion of sensor702 are activated approximately simultaneously when an activatorimpinges upon sensor 702 with the simple switched sensor indicating anon state and the proportional sensor indicating how much force is beingbrought to bear on sensor 702.

A novel sensor of this type, having both a simple switched and aproportional component in combination with my novel keyboard integrateddevices, such as those shown in FIGS. 18, 19 and 29 demonstrate thedesign of having a 6 DOF controller which outputs both a scan codekeyboard type information) and a proportional signal. This could be veryuseful in any multiple-axes controller even strictly hand-held devicessuch as those taught in my co-pending provisional application filed Sep.5, 1995. Outputting both scan codes and proportional signals (possiblyto separate keyboard and serial ports) could be of substantial valuebecause for all pre Windows95 machines virtually all 3-D graphicsprograms already have software drivers to be driven by scan codes (withprogrammable key maps) so that the 3-D software can controlled by commonkeyboards. Outputting this data type allows my 6 DOF controllers tointerface with existing software that is controllable by scan codes.Outputting both of these data types is not dependent on this compoundsensor rather it is simply demonstrated here. Information gathered fromany proportional sensor can be massaged into these two different dataoutput types which are believed to be novel in regard to output ofmultiple-axes controller devices and specifically for 6 DOF devices.

FIG. 43 shows a pair of compound sensors 702 integrated into compoundsensor sheet 700, the compound sensor on the left side is identified assensor 702.1 and the compound sensor on the right side is identified assensor 702.2. Sensor pairs are valuable because a 6 DOF device has 6axes which are interpreted bi-directionally (move along the axis to theleft or right, but not both simultaneously). Simple switches and thepressure sensors so far shown are unidirectional sensors so ideally apair of unidirectional sensors are used to describe each axis, thus sixpair of uni-directional sensors (twelve individual sensors) can describesix degrees of freedom. Unidirectional sensors are highly desirable bothfrom and cost stand point and from a superior functional stand point,because they allow a natural null or play space for accommodatinginaccuracies of the human hand and for optimally accommodating thepassive turn-on tactile feedback where the user can feel the differentaxes turn on and off with manipulation of the input member as describedearlier herein.

The pair of sensors 702.1 and 702.2 offer advantage, for example, in acomputer keyboard embodiment where the simple switched portions mayemulate key inputs and the proportional portions may serve to createsophisticated 6 DOF outputs. Further, for some applications anincremental output (simple switched) is more desirable than aproportional output. Sensor 702 provides both types of output inhardware. Finally, the compound sensor pair offers structure to lessenthe necessary electronics requirement for reading the unidirectionalproportional sensors. As shown if FIG. 43 the simple switched portionshave electrical connections 704 which make the switches electricallydistinct from each other, but the proportional sensor portions haveelectrical connections 704 which are in parallel, thus the proportionalsensor portions are not electrically distinct one from the other. Thesimple switched portion yields information about which direction alongor about an axis and the proportional sensors yield informationrepresenting intensity. Thus allowing only one analog channel to readtwo unidirectional proportional sensors, and correspondingly, only sixanalog channels to read twelve unidirectional sensors. A savings inelectronic circuit complexity.

FIG. 44 shows proportional sensors 638.1 and 638.2 in a pairedrelationship within a membrane structure. Sensors 638.1 and 638.2 havein common a center electrical connection 710 which connects to one sideof both sensors 638.1 and 638.2 of the pair. Each individual sensor hasa second and distinct electrical connection, being for sensor 638.1electrical connection 706 and for sensor 638.2 electrical connection708. The sensors are essentially in a center taped arrangement, so thatthe center connection 710 can be read with one analog to digitalconverter yielding bidirectional information, if, for example,connection 706 carries a substantial voltage and connection 708 isgrounded. Thus the mechanical and cost advantages of unidirectionalproportional sensors is utilized with economical electrical circuitry.

FIGS. 45-47 show bidirectional sensors mounted on circuit board sheetmeans for creating 6 DOF functional structures with previously describedstructures of the embodiment of FIGS. 20-28, thus for full 6 DOFoperability six bi-directional sensors would be used. The embodimentshown in FIGS. 1-3 specifically shows a nine sensor 6 DOF embodimentwith three bi-directional rotational sensors and six uni-directionallinear sensors. The embodiments shown in FIGS. 13-36 show twelve sensor6 DOF embodiments with all sensors being unidirectional sensors.

FIGS. 45 and 46 show generic rocker-arm type actuators 364 mounted oncircuit board 322. Actuators 364 are shown without a differentiatingsuper-structure 338 because the illustrated novel bidirectional sensorapplication could serve on any or all of the actuators 364 in theembodiment shown in FIGS. 20-27.

FIG. 45 shows rocker-arm actuator 364 mounted on circuit board sheet 322and a bidirectional sensor 750 such as a rotary encoder or potentiometersolder mounted to sheet 322 and operationally connected to rocker arm336 by a rack and pinion type gear assembly with the rotary shaft torotary sensor 750 bearing a small gear or pinion gear 752 which isactivated by riding on an arced gear rack 754 fixed to one end ofrocker-arm actuator 336 and passing freely through an aperture 756 insheet 322.

FIG. 46 is similar to FIG. 45 except that the bi-directional sensorshown is an optical sensor having a light transmitting unit 760 and alight sensing unit 762 which are both solder mounted to circuit boardsheet 322 and are separated by an arc shaped light regulating unit 764such as a graduated optical filter or a shuttering device which is fixedto one end of a actuator arm 336.

FIG. 47 shows sensors of the same type as described in FIGS. 45 and 46but with the exception that they are shown with structuring to operatewithin the handle such as in the embodiment shown in FIG. 28.

FIGS. 48 and 49 respectfully show a cross-section view and an explodedview of novel structuring for anchoring in a desired position a flexiblemembrane sensor sheet 658 or at least a portion of membrane sheet 658carrying at least one sensor 660 and for retaining in operationalpositions structure appropriate for actuating mechanisms. Sensor 660 maybe of either the common simple switched type or my novel pressuresensitive proportional membrane type. This embodiment is also foraligning and retaining sensor actuating structures, of which I believe,especially valuable are actuating structures of the resilient tactiletype. A package member 650 is a housing like structure shown here withfour side walls. Aligned along two of the opposing walls are downwardlydistending snap-fit legs 652 having a hook-like snap-fit shape at thebottom most extremity. Package 652 might be made of an injection moldedplastic such as a resin from the acetal family having excellentdimensional stability, rigidity and also resiliency for the bending ofsnap fit legs 652 during mounting of package 650 to a rigid supportstructure 630. The internal portion of package 650 is a cavity withinwhich is retained at least an actuator shown here as a plunger 602 whichis retained at least in part within housing package 650 by an upper ortop portion of package 650 partially enclosing the package cavity buthaving an aperture through which extends a portion of plunger 602 forbeing depressed or activated by external forces. Resilient metallic domecap 604 is also shown within the cavity and located between plunger 602and membrane sensor 660 which is supported on rigid support structure630. Rigid support structure 630 has two elongated apertures 656 sizedto allow the passage during mounting and retention thereafter ofsnap-fit legs 652. Membrane 658, which may be any sensor bearingmembrane, also has elongated apertures 654 positioned around a membranesensor shown here as sensor 660. Apertures 654 being of size allowingthe passage of snap fit legs 652.

The entire embodiment is assembled by positioning membrane sensor sheet658 or at least the portion of membrane sensor sheet 658 bearing asensor and apertures 654 along side of support structure 630 andaligning membrane apertures 654 with support structure apertures 656,then, with housing package 650 containing both plunger 602 and dome cap604, pressing legs 652 through the aligned apertures thus fixing themembrane sensor and actuating plunger 602 in accurate and secureposition for activation.

This novel membrane sensor anchoring and activating structure may beuseful for fixing into position a flexible membrane and associatedsensor(s) in a wide variety of applications, not just for fixing amembrane having multiple relatively long arms to fit a widely-spread setof sensors within a 6 DOF device such as for my co-pending application(Ser. No. 07/847,619, filed Mar. 5, 1992) and for finger activatedbuttons which may be located elsewhere within the device, such as oneither the handle housing or the base housing, etc. This structuringalso offers tremendous advantage in many non 6 DOF applications wherehand wiring is now common. For example, typical assembly of two axisjoysticks involves hand wiring of numerous different finger and thumboperated switches at various different positions located within a handleand often includes additional switches located with the base of thejoystick also. The hand wiring to these widely spread switch locationsis error prone and expensive in labor, thus this process could begreatly advantaged by employment of flexible membrane based sensors,which is made possible by this novel structuring.

FIG. 50 shows a right angle mount embodiment in common with the deviceof FIGS. 48 and 49. The right angle mount embodiment has a housing 650.1formed much like housing 650 with the exception that the aperture in theupper surface is not necessarily round to accommodate passage of plunger602 but rather the aperture may be slot-shaped to accommodate passage ofa right angle actuator 670 which upon external activation pivots about afulcrum 676. Right angle actuator 670 is structurally similar to theright angle translator parts shown in FIG. 17 as part 262, in FIG. 27 aspart 348 and in FIG. 28 as part 376. Specifically actuator 670 has anexternally exposed actuating nub 674 which is impinged upon by anactuating part in a manner essentially parallel to mounting 630 thuspivoting about fulcrum 676 and causing an internal actuating nub 672 toimpinge downward upon dome cap 604. Fulcrum 676 is held in place withinhousing 650.1 by a retainer 678 which may be essentially ring like andwith protrusions 680 which provide a saddle for pivotal retainment offulcrum 676.

The anchoring and retaining embodiments shown in FIGS. 48-50 provide anoptimal low-cost of manufacture embodiment where ever membrane sheetbased sensors are shown in the current teaching and can also operate toequal advantage providing structuring and translating for sensors basedon circuit board sheets.

Although I have very specifically described best modes and preferredstructures and use of the invention, it should be understood that manychanges in the specific structures and modes described and shown in mydrawings may clearly be made without departing from the true scope ofthe invention.

1. A method of using a controller, wherein the acts comprise: physicallyinputing, from a human into the controller, said physically inputingcontrolling at least one three-dimensional object shown by a display,said physically inputing activating sensors of said controller providingcommands to move at least some portion of said at least onethree-dimensional object shown by the display, said physically inputingactivating the sensors includes at least independent physical inputscontrolling: a move forward command, a move back command, a move leftcommand, a move right command, a move up command, and a move downcommand; and sensing vibration with a hand of the human as a tactilefeedback provided by said controller.
 2. A method of using a controlleraccording to claim 1 further including the acts physically inputinginputs related to at least three axes into the controller, saidphysically inputing controlling navigating a three-dimensional viewpointshown by the display.
 3. A method of using a controller according toclaim 2 wherein inputing at least one of said independent physicalinputs is in response to the sensing of said vibration.
 4. A method ofusing a controller according to claim 1 wherein the vibration tactilefeedback is related to the controlling of the at least onethree-dimensional object shown by the display.
 5. A method of using acontroller according to claim 1 wherein said controller is providingsaid tactile feedback using an electric motor with offset weight, therotating of the offset weight by the motor causes the vibration, and thesensors are independent sensors, wherein each one independent sensorcontrols each one of the commands.